Professional Documents
Culture Documents
https://doi.org/10.1007/s40964-020-00159-x
REVIEW ARTICLE
Received: 22 July 2020 / Accepted: 7 November 2020 / Published online: 24 November 2020
© Springer Nature Switzerland AG 2020
Abstract
The coronavirus disease 2019 (COVID-19) pandemic, caused by severe acute respiratory syndrome coronavirus-2 (SARS-
CoV-2), has spread through more than 180 countries, leading to diverse health systems overload around the world. Because
of the high number of patients and the supply chain disruption, it generated a shortage of medical devices and personal
protective equipment. In this context, initiatives from the additive manufacturing community emerged to fight the lack of
devices. Diverse designs were produced and are currently being used in hospitals by patients and health workers. However,
as some devices must follow strict standards, these products may not fulfill these standards. Therefore, to ensure the user’s
health, there is a need for understanding each device, their usage, and standards. This study reviews the use of additive manu-
facturing during COVID-19 pandemic. It gathers the source of several 3D printed devices such as face shields, face masks,
valves, nasopharyngeal swabs, and others, discussing their use and regulatory issues. In this regard, the major drawbacks of
the technology, addressed for the next pandemic scenario, are highlighted. Finally, some insights of the future of additive
manufacturing during emergency are given and discussed.
1 Introduction consensus has not been reached [6, 7]. Some recent works
point out that aerosol transmission may be more significant
The coronavirus disease 2019 (COVID-19) had its first doc- than previously considered [8, 9].
umented patient in December 2019, Wuhan, China [1]. Since Infected people might be asymptomatic [10, 11], but may
then, the virus has spread through the world, and the World also present severe acute respiratory syndrome (SARS),
Health Organization (WHO) defined the disease as pan- resulting in intensive care unit (ICU) admission [11, 12].
demic in 11 March 2020 [2]. Just 9 months after identified These are all factors that contribute to the virus spread
“patient zero”, the disease has spread, on October 9th, in 188 ratio, leading to health systems overload around the world.
countries and regions with more than 36.6 million confirmed The high number of patients created a supply chain disrup-
cases and more than 1,063,000 global deaths according to tion, generating a shortage of personal protection equipment
the official data of the countries in the COVID-19 Dash- (PPE) and medical devices in hospitals for fighting off the
board by the Center for Systems Science and Engineering virus.
(CSSE) at Johns Hopkins University (JHU) [3]. To fight the lack of devices and equipment, companies,
The severe acute respiratory syndrome coronavirus-2 universities, independent groups, and individuals started a
(SARS-CoV-2) can be transmitted though droplets [4], movement of production of diverse items to supply hospitals
aerosol, and direct and indirect physical contact through and people that are facing the shortage [13]. Various devices
contaminated surfaces, in which the virus may remain up have been produced, such as face masks, face shields, test
to 72 h [4, 5]. Regarding the transmission modes involv- swabs, door handle attachments, valves [13–17] etc. and are
ing droplets and aerosol, they are still under research and a being massively shared by social media [18, 19]. In this con-
text, additive manufacturing (AM), commonly named as 3D
printing, has emerged as one remarkable fabrication process
* Guilherme Arthur Longhitano because of its accessibility and flexibility to quickly produce
guilonghita@gmail.com
complex and monolithic parts or even mechanical systems
1
Center for Information Technology Renato Archer (CTI), [20–22]. Another reason is that people involved with AM
Campinas, Brazil
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are open-mind, creative, with interdisciplinary relationships Because of its wide range of materials and techniques,
and applications. Therefore, AM technology allows the AM can be used in a myriad of areas and applications,
user to easily produce parts directly from a STL file format from rapid prototyping to medicine and aerospace end-use
(designed in a CAD system), which can be easily found and parts [20, 27]. The direct-from-CAD production, freedom
shared in makers hubs or even at social media [19]. Finally, of design, ease of customization, low number of steps, and
during the last decade, because of patent period expiration, rapid production of unique or small batches of parts are
desktop 3D printers have become accessible as low-end- some of the main advantages of AM [20, 22, 27, 28]. How-
machines for common people by open access projects that ever, there are a few common drawbacks for AM techniques
dramatically reduced their costs [22, 23] and the entrance that are still present, like parts anisotropy [20], high cost of
barriers for low range AM equipment. industrial equipment, high cost of feedstocks (when com-
However, 3D printed parts may present different proper- pared to traditional techniques) [21], and high cost for big
ties and finishes because of differences of materials used, batches [22, 28]. Another serious concern still present in
technology, and individual machine software and calibra- AM is the repeatability among machines of the same brand
tion, even for a same STL project [24]. As PPE and medi- and models and even between consecutives processes [20].
cal devices must follow strict standards, these do it yourself
(DIY) products may not fulfill the requirements of these
standards, representing a risk to the users’ health. Therefore, 3 Pandemic and additive manufacturing
there is a need for understanding each device, usage, and
standards to ensure that these products can in fact be helpful At the same time that the COVID-19 pandemic increased
for the purpose intended with the lowest risk for patients and the demand for medical devices and created a new market of
healthcare personal. products for general public, it provoked various supply chain
This study aims at reviewing the use of additive manu- disruptions, rapidly generating a shortage of many critical
facturing during COVID-19 pandemic. It focuses on vari- items, such as PPE [14, 16, 29–31]. Following this issue,
ous PPE, medical devices, and other applications, providing companies, groups and individuals started to cooperate to
their source and discussing their use and regulatory topics. supply people and hospitals that are facing items shortage
Finally, a perspective for the future of AM during emergency [14, 24, 28, 32, 33]. In this regard, AM has emerged as a
situations is given. potential flexible solution for locally supplying various types
of these items, demonstrating the potential of AM for a local
and flexible production of strategic items, reducing supply
2 Additive manufacturing chain dependency [13, 27, 34].
One of the main reasons that made AM an important tool
As defined by ISO/ASTM 52900 standard [25], additive during the pandemic is the great number of users around the
manufacturing is a “process of joining materials to make world [19], many of them very specialized, innovative and
parts from 3D model data, usually layer upon layer, as creative. During the last decade, the decrease in the cost
opposed to subtractive manufacturing and formative manu- of processors and the expiration of patents made desktop
facturing methodologies”. The 3D printing terminology is 3D printers as low-end-machines [22, 23]. Furthermore, the
commonly associated with machines that are low end in feedstock price, mainly filament polymers, for these printers
price and/or overall capability [25]. are in constant lowering [22]. Thus, the ability to produce
The first commercial system of AM dates from the year parts for supplying the pandemic shortage is not exclusive
1987 and consists of the stereolithography (SLA) technique, for industry: makers, people who own or have access to rapid
which uses photo-curable polymers [20, 21]. Nowadays, a manufacturing machines such as 3D printers, have been
wide range of techniques and materials are available in AM proven to significantly contribute during the disease [23].
technologies. The International Standard ISO/ASTM 52900 A second reason is that people who have a 3D printer
[25] divides AM processes in seven different categories: vat do not require CAD-design knowledge to produce parts.
photopolymerization, material extrusion, material jetting, 3D printable files can be easily found in internet via 3D
binder jetting, powder bed fusion, sheets addition, and direct printing open-design repositories, makers hubs or even at
energy deposition. These processes use polymers, ceramics, social media [19], only requiring a desktop printer to start
metals, and composites as feedstocks to build a part [20, production.
21, 25, 26]. Some techniques available on market are SLA, A third reason is that complex parts that would require
fused deposition modeling (FDM), fused filament fabrica- a long period of time of manufacturing planning via tradi-
tion (FFF), PolyJet, direct light projection (DLP), multi jet tional processes can be quickly put into production by AM.
fusion (MJF), selective laser sintering (SLS), selective laser It has a minimal lead time to deliver small batches of parts,
melting (SLM), and electron beam melting (EBM). producing an almost immediate response to the crisis [22,
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28, 35]. Consequently, when media started to share informa- anyone interested to contribute and share their developments
tion on shortage of items, people could start helping as soon [50]. Global network put together volunteers and experts via
as they had STL files. The technique ability for rapid proto- dedicated hubs to provide diverse types of products to supply
typing also allowed the fast production of the first designs the community [28]. These interactions, associated with the
and machine prototypes. Furthermore, an AM facility for use of desktop 3D printers, act as an iteration chain process
low-end machines does not require complex planning or for optimizing the project and reaching a final design in a
infrastructure. As example, François et al. [36] presented short period of time.
a technical note on the production of devices related to the In addition, various companies worked on more engi-
COVID-19 pandemic for Greater Paris University Hospitals neered and reliable data and designs solutions using 3D
and various state institutions. They reported that 60 FFF printing workforce around the world. Some examples of
machines were ordered, delivered, and settled in a period of notable projects, just to cite a few, are ISINNOVA’s valves
4 days. Therefore, if there is an urgent demand of emergency [51, 52], Prusa’s face shields [53] and Materialise’s [46]
items, a 3D printer facility can be quickly installed and put solutions for non-contact tools and masks. Furthermore,
into work. Using a single desktop 3D printer, Thomas et al. there are projects like the Open Source Medical Supplies
[37] took 21 days from conception to delivery of 50 reusable that gathered together multidisciplinary professionals, such
personalized face masks based on the Stopgap surgical face as engineers, medical professionals, makers, researchers etc.
mask design [38]. to lead and inform people who are trying to fight the equip-
ment shortage [54]. Finally, scientific papers [12, 50, 55,
56] were also used as a way of data and information sharing.
4 Data sharing In this case, more detailed data in fabrication methods and
results are given, as well as more reliable data because of the
One of the main advantages of AM is the direct-from-CAD peer-reviewing process. However, they are less accessible
production. The user can easily produce parts from CAD to common public since they can be found only in specific
files, which can be designed or obtained from internet scientific media and some publications are not open access.
specialized repositories. Currently, there are various file
repositories like Thingiverse [39], NIH 3D Print Exchange
[40], GrabCAD [41], Pinshape [42], Cults [43], Yeggi [44], 5 3D printed devices
MyMiniFactory [45] and others. These websites store 3D
printable files, usually in STL file format, which are shared The following sections present and discuss diverse types
by users. These repositories allow the upload, download, of solutions produced by AM during COVID-19 pandemic.
exchange, and even edition and new upload of 3D printing
files and information by anyone. 5.1 Personal protective equipment—PPE
During the pandemic, data sharing has rapidly increased
to spread initiatives and solutions as an attempt to fight off PPE are the most printed devices during the pandemic
the virus. From this perspective, social media [19, 33], com- because of their relative simplicity, low geometrical toler-
pany websites [46, 47] and file repositories have played a ance requirements and lower-risk classification within Food
main role in sharing data [23, 33, 35]. As social distancing and Drug Administration (FDA) or other regulatory bodies,
was the main strategy for most governments to reduce trans- when compared more complex devices like ventilators and
mission rates, people at homework increased social media valves [23].
use [19]. After the virus was announced by China, a wave of Face shields constitute majority of the projects among
information sharing occurred though social media as never PPE [23, 57]. FDA considers face shields as Class I medi-
seen before. Unfortunately, part of these were unreliable cal devices [4, 58], and WHO considers them as an alter-
information like conspiracy theories or misleading rumors, native to medical masks during shortages [59]. They are
generating panic and depletion of stockpiles [48]. How- a head-worn frame with a clear plastic sheet to protect
ever, social media also played a role in sharing initiatives the user’s face from direct contamination via sprays and
aiming at providing PPE and medical devices for people in splashes [4, 13, 23, 60]. Another requirements are that
need [18, 19, 49]. In line with social media, file repositories they must be easy to disinfect, comfortable during long
websites were used for sharing downloadable CAD files for periods, durable and allow additional PPE wearing [61]. It
3D printing parts to be used during the pandemic [19, 49]. is important to remark that in highly infectious situations
Furthermore, there are several websites hosting platforms the face shield must be used with additional PPE equip-
like github and gitlab, dedicated to open projects related to ment [4, 61]. The frame consists of a simple geometry
COVID-19. These platforms facilitate quick design inter- that can easily be 3D printed [53, 56, 61, 62]. A further
action among different professionals by allowing access to approach uses SLA to produce a hollow frame to be used
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with an external airflow, defogging the visor and prevent- [66], FRC Team’s [67] and Creality’s [68] designs. However,
ing ambient air from entering [63]. The plastic sheet is there is no information if these models were validated.
cut manually, using scissors and an office puncher [56], or N95 respirators (class II device by FDA [58]) and surgical
automatically, using laser cutters [60]. Some material of masks (class I device by FDA [58]) are critical PPE. Both
choice are polycarbonate, Propionate, acetate, polyvinyl are recommended by the WHO for health workers during
chloride, and polyethylene terephthalate glycol (PETG) this pandemic [59], and are intended to filter particles of
[60]. An elastic band may be suitable in some models [61, bacteria and virus to avoid contamination [31]. N95 respira-
64]. The face shield design must cover the sides of the tors have a minimum efficiency reporting value (MERV) of
face and below the chin [59]. Printing time and price of 95% for particles larger than 0.3 µm [32, 69]. Even though
face shields are design, machine, material, and parameters COVID-19 virus particle size are under 0.16 µm [1, 70],
dependents [4, 56, 57]. Figure 1 shows diverse 3D printed these respirators are capable of filtering droplets that work as
face shields models built using different AM techniques vehicles of virus transportation [32]. Surgical masks cannot
and materials. Designs of face shields can be found in assure the same protection as a N95 respirators [64, 69], but
various file repositories [39, 40, 42, 43, 45]. they can provide significant reduction, leading various coun-
Safety goggles act in a similar way of face shields: they tries and states to incentive or obligate people to use even
work as a physical barrier for the eyes. Eye protection is homemade fabric masks to reduce contamination ratio [59].
indicated as a protection from infected patients’ exhaled Because of the critical function and high demand, diverse
droplets [10]. Farsoon, Huaxiang and LEHVOSS companies 3D printable projects and designs were proposed. 3D printed
designed, validated, and made available for download two adaptor valves to be connected with full-face snorkeling
sizes of safety googles to be made by SLS, SLA or FFF tech- masks and a high-efficiency particulate air (HEPA) filter
nologies. The lens are to be cut separately in acrylic material (Fig. 2) were suggested for health workers usage [49, 71,
[65]. There are other available models, such as PUC-Rio’s 72]. These full-face snorkel masks have three diaphragm
Fig. 1 Various face shields designs made by different AM techniques. 1—SLS/PA12; adapted Prusa model 2—FDM/PC; adapted Prusa
a Hígia model [62]—SLS/PA12; b Prusa RC1 model [53]—SLS/ model 3—FDM/PC. Face shields assembly with a Prusa RC1 model
PA12; c Prusa RC2 model [53]—FDM/ABS; d adapted Prusa model and b adapted Prusa model 3
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health workers. A possible way for reducing intubation is may minimize environment contamination [12], and can be
using non-invasive ventilation (NIV) procedures, such as sterilized and reused [32].
continuous positive airways pressure (CPAP). The WHO Another approach related to the shortage of avail-
recommends the use of NIV as a first approach before intu- able mechanical ventilators are 3D printed splitters (class
bation of patients [10]. Wang et al. [88] made a study in II devices by FDA [58]), which allow the use of a single
which 27 COVID-19 patients presenting SARS were submit- mechanical ventilator by two different patients [15, 90]. Fur-
ted to NIV. From these patients, only 4 had to be intubated. thermore, there are also open-source NIV helmets projects
However, because COVID-19 can be transmitted through like the Bubble Helmet from COSMIC Medical [91] that
aerosols and droplets [4, 14], NIV with inappropriate seals may use 3D printed valves as ports for the assembly.
should not be used [87, 89]. Hence, exhaled air from the Venturi valves (Fig. 4b) operate by Bernoulli’s principle
patients submitted to NIV cannot be returned to the environ- of jet gas mixing [11] and can deliver a fixed fraction of
ment or must be filtered with a HEPA filter. inspired oxygen (FiO2) [69, 87], depending on the valve
Italian ISINNOVA company created a solution using 3D geometry [87]. They are used with a mechanical ventila-
printing connector valves to be used with Decathlon’s Sur- tor and a Venturi mask during NIV procedures [11, 87].
face Snorkeling Mask Easybreath® as full-face masks for They are also described as part of the CPAP system when
CPAP procedure (Fig. 4c). The valves, named as Charlotte connected to a mechanical ventilator [12]. Therefore, these
(Fig. 4a) and Dave (Fig. 4d), can be downloaded at ISIN- valves are essential during COVID-19 pandemic because of
NOVA’s website. FFF/polylactic acid (PLA) are the recom- the high demand for respiratory devices. In Brescia, Italy,
mended fabrication method/material [51]. This assembly a supply chain disruption made these valves scarce. Again,
can be used with an oxygen flow or mechanical ventilator, ISINNOVA 3D printed by FFF Venturi valves in a short
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Fig. 4 a ISINNOVA’s Charlotte valve [51] made by different pro- being used during CPAP procedure. d Diverse types of valves:
cesses and materials—from left to right: MJF/PA12, FDM/PC and 1—Charlotte [51]; 2—Dave [51]; 3,4,5—Modified Charlottes; 6–
SLS/PA12. b Venturi valve models by SLS/PA12 and PolyJet/Vero- adaptors made by SLS/PA12
Clear®. c Snorkeling mask connected to an ISINNOVA’s valve for
period of time, based on reverse engineering, and have saved printed ports that allows suction, oxygen delivery and nebu-
lives [52]. These valves were also further produced in SLS lization. The instructions and plans are available under a
and SLA [52]. Filip Kober further created 3D models to be Creative Commons License, Attribution-NonCommercial-
printed in SLA, downloadable at GrabCAD [92]. SLA is the ShareAlike 4.0 International. A collaboration of Sector 67
technique of choice because part porosity may alter the func- with University of Wisconsin-Madison Department of Sur-
tionality of the valves, changing delivered FiO2 [15]. The gery, Dr. Hau Le, and UW-Madison College of Engineer-
models were simulated using computational fluid dynamics ing [94] developed a negative pressure isolation head box,
(CFD) to ensure the correct values of FiO2 [52]. named as “badger box”, which uses AM to produce glove
grommets. Another example of isolation chambers, although
5.3 Isolation chambers and wards more simplistic, were produced in Texas A&M University
[95]. The chambers work as a physical barrier for contami-
A measure to prevent the SARS-CoV-2 dissemination is the nated patients and consist in CNC cut vinyl and 3D printed
isolation of suspected or confirmed patients. As explored parts.
before, patients in hospitals may spread the virus through In large-scale projects, the creation of 3D printed isola-
aerosols and droplets [4, 14]. Therefore, some devices can tion wards by the Chinese company WinSun can be high-
reduce environment contamination. Cubillos et al. [93] lighted [96, 97]. The wards are used as a professional and
developed a negative air flow isolation chamber for COVID- comfortable environment for patient isolation and treatment.
19 patients. Their device consists in a rigid cubic frame They can also serve as a properly sanitized and protected
chamber draped with a clear plastic bag in which a continu- resting place for healthcare professionals working directly
ous negative air flow prevents air from inside the chamber to combat the pandemic. The standard model is 10 m2 and
from contaminating the external environment. It uses 3D 2.8 m tall. The 3D printed wards construction process is
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automated, resulting in low labor cost and rapid construc- [103]. Arnold et al. [101] developed a swab with an open
tion. The buildings can be moved to different locations and lattice design to be produced by DLP process. The model
can be easily connected to a power supply network [13, 34]. was tested and obtained a 90% match of results taking com-
Finally, build process uses as feedstock material industrial or mercial swabs as golden standard, showing the design is
solid construction waste and, after demolition, can be reused adequate for test. Ford et al. [104] designed and developed
in new 3D printed buildings [96]. over 20 nasopharyngeal tips. Their final design showed a
94% concurrence with the current synthetic version in an ini-
5.4 Field respirators tial study and multisite clinical trials are currently underway.
The STL models from the previous works are only available
An alliance between the Consorci de la Zona Franca de by request to the companies.
Barcelona, HP, CatSalut and Leitat Technological Center Finally, some nasopharyngeal swabs designs can be found
developed a field respirator, named as LEITAT 1, using AM at file repositories, such as the model from Fig. 5, designed
for prototyping and parts production. The device, a mechani- by MarianneE (Johns Hopkins University Applied Physics
cal bag valve mask, is to be used for short term emergency Laboratory) user in the NIH 3D Print Exchange repository
ventilation. The emergency ventilator, tested in ICU patients [105]. This design is for production using SLS/PA12. How-
and approved by the Spanish Medicines Agency, has parts ever, it is important to remark that there is no evidence these
produced by MJF and is industrially scalable [98, 99]. More- items have undergone any clinical test or validation, and the
over, Petsiuk et al. [100] designed an automated fully open manufacturers should be certified by ISO 13485 (Medical
source bag valve mask-based ventilator, which also serve Devices Quality Management System) for ensuring safe and
as a temporary emergency ventilator. In their work, they reliable tests.
give a detailed protocol and links to the downloadable files,
which include 3D printable parts of the ventilator assembly. 5.6 Hands‑free tools
The reported results exceed human capabilities in bag valve
mask-based manual ventilation. The COVID-19 virus may remain on different surfaces for
periods up to 72 h [5]. Thus, avoiding direct contact with
5.5 Nasopharyngeal swabs surfaces is an important way to reduce contamination during
the pandemic, especially in public and medical centers [15].
Massive testing is an important measure for fighting the Some objects such as buttons, door handlers, switches etc.
COVID-19 pandemic. For this, specimens from the upper are potentially virus spreaders because of the high number
respiratory tract must be collected and tested by reverse tran- of interactions with different people [36].
scription polymerase chain reaction (RT-PCR) [10]. In this As a solution for reducing direct hand contact, various
sense, nasopharyngeal swabs provide the highest sensitivity hands-free tools were designed. François et al. [36] designed
for the virus detection [50]. These are FDA Class I medical and produced by FFF a high volume of various hands-free
devices [58] with a rod-shape and a head coated with short tools to be used in Greater Paris University Hospitals and
synthetic filaments or spun fiber, used to collect secretions other sites.
from the upper respiratory tract from the patient. The swab
usually has a breakpoint on the shaft for enabling the head
storage in a vial with viral transport media. Then, the sealed
vial is sent for testing. To ensure a safe and reliable test, the
swab must be flexible and sterilizable [15, 101]. Cotton head
swabs are not indicated for COVID-19 [10, 50].
Cox and Koepsell [29] created a FFF printable and steri-
lizable PETG nasopharyngeal swab. They made clinical
tests using commercial swabs as control and found the 3D
printed model has the same efficiency of the control group.
Callahan et al. [50] made a multi-step preclinical evaluation
on 160 designs and 48 materials of test swabs and validated
4 prototypes. From this study, a consortium including Car-
bon, FormLabs, Envisiontec, Origin and Abiogenix com-
panies was created and can produce up to 4 million FDA
Fig. 5 Nasopharyngeal swab from MarianneE user from NIH 3D
registered test swabs per-week via vat photopolymerization
Print Exchange repository [105] made by SLS/PA12. This design has
with medical grade resin [102]. In the same work, swabs not undergone any validation process and is exhibited only as exam-
designed for MJF medical grade nylon were also validated ple
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Hands-free door openers are devices that are fixed to door In this context, Copper 3D company uses the antiviral
handles and allow door opening and closing with elbows or properties of copper to produce a face mask (named as
forearms [36]. Materialise company designed different types NanoHack) using the company’s bioactive materials PLAC-
of hands-free door openers for cylindrical, rectangular, cir- TIVE® and MDflex®. The filtering system still require non-
cular, and spherical handlers that can be 3D printed by MJF, printed material (non-woven polypropylene embedded in
SLS or FFF technologies [46]. Figure 6a and b show Materi- copper nanoparticles) [110].
alise’s rectangular and circular hands-free door openers, and Another approach for antimicrobial devices is using anti-
the rectangular model usage. Furthermore, hands-free tools microbial coatings on surfaces to reduce biofilm formation.
for opening doors, pushing buttons, hooking handles, open- Muro-Fraguas et al. [111] used plasma-polymerization to
ing water taps, and other daily tasks were created by various create an acrylic acid (AcAc) coating on 3D printed PLA
designers for personal use. These hands-free designs can be Petri dishes and obtained antibacterial properties using dif-
found in various repositories websites such as Thingiverse ferent Pseudomonas aeruginosa and Staphylococcus aureus
[39], NIH 3D Print Exchange [40] and others. Figure 6c strains.
and d shows hands-free tools by SimonSolar2C [106] and
bgiovanny [107] users from Thingiverse repository and an 5.8 Training and education
example of use.
One of the various applications for AM is the education
area. It can be used from printing simple forms to help chil-
5.7 Antimicrobial devices dren to develop abilities and skills [112, 113] to adults and
professionals, where complex replicas to improve diagno-
One major drawback of using AM polymers in some appli- sis, surgical planning and patient education can be printed
cations, such as masks, valves, and no-contact tools, is that [113, 114]. In this regard, AuMed [115] designed a mani-
SARS-CoV-2 presents a high stability (up to 72 h) on these kin to help training of inexperienced healthcare workers in
surfaces. On the other hand, the virus stability on copper COVID-19 diagnosis by nasopharyngeal swab testing. In
surfaces are reduced to 4 h, as found by van Doremalen the education context, according to Hervás-Gómez et al.
et al. [5]. The previous work is in accordance with litera- [113], the use of AM in education is growing, following
ture related to the use of some metallic coatings or nano- the development of the Industry 4.0. Moreno Martínez and
particles into polymers. Some metals such as copper and Morales Cevallos [116] point out the opportunity to use the
silver have antimicrobial characteristics and can be used in AM notoriety during the COVID-19 pandemic to use this
the development of bioactive polymers [108]. Borkow et al. technology to improve students interest, participation and
[109] showed that a face mask doped with copper and cop- proactivity in experimentation and manipulation. The use
per oxide particles reduce the risk of influenza (H1N1 and of 3D printed tactile models can also be a tool for commu-
H9N2) contamination. nication with individuals who are visually impaired [112].
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Figure 7 presents two visual-tactile models of the SARS- to sell or donate these items. As a way for helping people
CoV-2 morphology. Both models explore the proteins, lipid to increase the production of these wearables, 3D print-
membrane and RNA from the virus. The models shown in able mask pleaters and bias tape makers were designed and
Fig. 7a and b also contain support bases with Braille tran- made available for download at diverse repositories, such
scription for people who are visually impaired. Finally, as Thingiverse [39]. Bias tape makers are folders that assist
because of the rapid shift to online education that occurred the fabrication of cloth bias tape, as shown in Fig. 8, used
in various countries, simple solutions, such as 3D printed in finishing edges of fabric masks. Mask pleaters help the
mounts to point webcams downwards, may help instructors production of pleated face masks. Both are time-consuming
to present a board-based pedagogical method [117]. tasks, and these simple designs act as tools for increasing
production.
5.9 Mask manufacturing tools
5.10 Endoscopic procedure mask
In a document with advice on the uses of masks during the
pandemic [59], the WHO guided governments to encourage The risks to health workers associated with aerosols and
the general public to wear face masks. Because of the short- droplets during IMV procedures were discussed in Sect. 5.2.
age of surgical and N95 masks, homemade fabric masks However, there are other medical procedures, like endo-
emerged as an interim solution. Consequently, some people scopic skull base surgery, that also create high risks of
started to sew their own fabric masks and, in some cases, pathogens transmission. In this context, Helman et al. [55]
Fig. 7 Visual and tactile educative models of SARS-CoV-2, showing Plus® two-halves model. Models from own authorship and available
RNA, proteins, and lipid membrane. a SLS/PA12 model with base by request to the main author
containing braille writing and b PolyJet/VeroClear® + TangoBlack-
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developed a 3D printed mask for endoscopic skull base sur- moisture, which could act as a virus transmitter during use or
gery. They redesigned the mask edge circumference from reuse [24]. In addition, 3D printed parts have different char-
open-source mask models and added an inlet and outlet to acteristics from parts produced by conventional methods:
the sides of the masks for tubing. Then, they used a surgi- the layer upon layer process may generate poor interfaces,
cal glove to provide a flexible physical barrier that allows delamination, and unintentional porosity [122]. Thus, as
usage of medical instrumentation. They performed various pointed by Larrañeta, Dominguez-Robles and Lamprou [14],
tests in two cadaveric models and found the device offers the these parts may not provide the same security levels. In a
surgeon appropriate surgical degrees of freedom, maneuver- preprinted work from Bezek et al. [78], face masks produced
ability and reduces risks of contamination. The mask model by FFF presented defects that decreased their efficiency in
is available by request to the main author of the work. filtering particles. Novak and Loy [57] indicate the need for
design for additive manufacturing (DfAM), which consid-
5.11 Metallic devices ers the AM process characteristics and particularities during
project. Therefore, makers must be aware of optimized print-
As explored in Sect. 5.7, the COVID-19 virus stability on ing parameters for the application and the required quality
copper surface is up to only 4 h [5]. Following these find- of each printed part [123].
ings, ExOne company and the University of Pittsburgh In addition, since there is no review process for any STL
worked in collaboration to develop sterilizable copper fil- file uploaded in file repositories, there is no assurance that
ters made by binder jetting technology. They use the pro- the final models will be functional. Another issue is the high
cess intrinsic porosity after sintering to produce filters with number of different types of projects that can be found for
specific porosity levels to meet N95 filtration standard. One a same device, such as face-shields and face masks. As an
major advantage of the filter is that it is reusable, reducing example, Novak and Loy [57] studied the manufacturability
waste disposal [119]. of 37 and 31 different face-shield and face mask models,
To summarize the data from all the 3D printed devices respectively, from companies, groups, and individuals. They
presented in the previous sections to fight against COVID- found large differences in terms of cost and manufactur-
19 pandemic, Table 1 gathers information about used AM ing time between the models. This may be a concern when
technologies and their respective references. choosing which model to produce. Another issue is choosing
valid models that were previously tested and reviewed by
medical workers, since there are various designs that lack
6 Drawbacks this information. In this regard, companies and scientific
papers are a better source of projects that were generally
As AM has assumed an important role during COVID-19 developed by multidisciplinary teams and went through a
pandemic, there are some major drawbacks that must be validation process.
discussed. With regards to issues, the regulatory agencies and
Different parts produced from a same STL file may intellectual property are two relevant topics. Beyond
present significant variations in geometry and mechanical medical review and validation, medical devices must be
properties because there are differences in material type approved by the country’s regulatory agency, such as FDA
and quality, software, calibration and equipment [24, 28]. for USA, the Medicines and Healthcare products Regula-
In a work by Mueller et al. [28], the authors raise several tory Agency (MHRA) for the United Kingdom and the
questions about the material selection and quality control of Brazilian Health Regulatory Agency (Anvisa) for Brazil.
3D printed parts for COVID-19 pandemic. Most of medical Hence, it is worth to say that every single person involved
devices must comply with strict standards to ensure a safe in the production of medical devices must be aware of
and reliable use, avoiding any preventable harm for patients his/her legal responsibility even as a philanthropic action.
and professionals. As an example, FFF filament may retain Usually, the process for approval by a regulatory agency is
13
30 Progress in Additive Manufacturing (2021) 6:19–37
expensive and requires considerable time [23]. Regarding the COVID-19 pandemic rapidly changed our thinking on
this, during the pandemic, some agencies had published intellectual property and highlight the need for regulators,
official declarations on the use of unapproved medical ethicists, lawyers, and members of the industry community
products during the emergency [124, 125]. Previous to to discuss and create guidelines for the maker community
the pandemic, in December 2017, FDA had published a during global crisis scenarios.
guidance with technical considerations for additive manu- Finally, as shown by the current study and summarized
factured medical devices [126]. However, Pecchia et al. in Table 1, majority of parts and projects are developed
[18] point that emergency situations demand universal in polymer AM. Larrañeta, Dominguez-Robles and Lam-
regulations, mainly for low- and mid-income countries. prou [14] pointed FFF, SLS and SLA as the main AM
Further, the authors also argue about the importance of techniques used for producing COVID-19-related parts.
regulations and standards for guiding the manufacturers Besides, Novak and Loy [23] studied the AM projects
for ensuring high safety levels, since even small defects availability and also found that FFF, SLA, MJF, SLS and
may harm the user. For the intellectual property theme, other polymer-based techniques are the flagship AM pro-
most of the medical equipment from the existing medical cesses during the pandemic. Beyond polymers, AM can
system is based on patented equipment from medical sup- work with metals, ceramics, and composites. In 2017,
pliers [31]. Regarding this, Tino et al. [15] alert for the the unit sales for metal AM systems grew by 79.9%,
reverse-engineering process and its possible legal issues. well above the 12.6% growth of unit sales of overall AM
They point that goodwill from regulators, legal experts, industrial system [21]. However, even with an exponen-
and governments are essential for saving lives during an tial growth, metallic AM solutions during COVID-19 pan-
emergency such as the COVID-19 pandemic. As an exam- demic are almost zero. This statement could be related to
ple, ISINNOVA company rapidly patented their Charlotte the high costs of metal AM machines and feedstocks, lead-
valve to prevent any price speculation and left it free to ing to a low number of disponible workforce. Thus, metal
use [51]. Furthermore, Mahr and Dickel [127] discuss how AM fully potential was not explored during the pandemic.
13
Progress in Additive Manufacturing (2021) 6:19–37 31
7 Potential uses of AM in future pandemics metal AM has grown exponentially in the last years [21], it
is still an expensive technology with less facilities around the
In the history of mankind there are records of several pandem- world. However, this growth will create new opportunities
ics such as smallpox, cholera, Black Death (plague), AIDS, for the technology expansion, development, and accessibil-
influenza, SARS, West Nile disease and tuberculosis [128]. ity, making it an important tool for possible next pandemics.
The “Spanish flu” influenza pandemic, the most lethal pan-
demic in recent history, killed more than 20 million people 7.3 Design for additive manufacturing
worldwide [128, 129]. Influenza A (H1N1), a more recent
pandemic, occurred in 2009 and contaminated over 1.6 mil- The advantages of AM, such as freedom of design, allow
lion people and had 18,449 confirmed deaths [130]. In a more using lattice structures, organic shapes, stacking, cooling
localized spread, Ebola outbreak in West Africa in 2014–2015 channels, topology-optimized geometries and more. These
resulted in 28,600 cases, resulting in 11,350 deaths, though it is features are related to AM-engineering design, named as
estimated that up to 70% of cases may not have been accounted design for additive manufacturing. The DfAM also relates
[131]. Even though infectious diseases have always plagued to process particularities, such as layer-by-layer manufactur-
humanity, during the last decade, there has been a significant ing, thermal history, and residual stress [135]. This area is
increase in the number of emerging and reemerging infections, quickly evolving, aided by software development, and will
reaching more than 20 infectious agents [132]. In fact, since strongly impact AM industry and development. In a review
1980 the number of infectious diseases has increased by nearly work, Thompson et al. [135] study the importance of DfAM
fourfold because of the population growth, increased number and highlight that the future will bring educational materi-
of domesticated species, and globalized economy—with an als for institutions, industry and hobby community. Conse-
increased people mobility [133]. Therefore, there is no reason quently, DfAM will evolve and leverage AM productivity,
in expecting COVID-19 pandemic will be the last, or it will suitability of design, lower production costs, and open new
take a long time for a new outbreak. opportunities of applications.
In this regard, beyond the already developed applications
for AM during emergency situations, there might be new
uses that will come from the technology advancements. As 7.4 Rapid tooling
explored previously, AM is a relatively recent technology, hav-
ing its first commercial system dated from 1987. The technol- AM is a powerful tool for prototyping and small batch pro-
ogy has currently attracted attention from research and indus- duction. However, when dealing with big batches, conven-
try, with new technologies and materials coming up daily. The tional techniques, such as injection molding, are economic
next sections show and discuss some specific AM fields that favorable [136–138]. As an example, a preprinted work
may affect possible future applications for AM during future by Kunkel et al. [139] presented a qualitative comparison
pandemics. between AM and injection molding capabilities for large-
scale production of face shields. For a single AM machine,
7.1 New materials the production capability was of about 10 per day, while
for an injection molding machine it reached a capability of
New material development will make AM more competitive 2000. Nevertheless, AM can be used for rapid tooling, an
toward conventional production technologies as it will create accelerated production of tools for injection molding. Fur-
opportunities to new design freedoms and applications [26]. thermore, conformal cooling channels can be added in the
As a previously discussed example, bioactive materials, such design. Conformal cooling channels, which cannot be pro-
as bioactive plastics, which present antimicrobial properties duced by conventional production technologies, are cooling
[108–110], are still being developed and will reach common channels in tooling that follow the shape of the designed
public, opening a window for mass fabrication of bioactive parts. These channels provide enhanced thermal control
devices, such as valves, hands-free tool and masks. Regard- with improved heat exchange, implying in faster produc-
ing this, Zuniga e Cortes [134] highlight the importance of tion cycles, better products, and increased injection tool life
developing these materials as they may be an important tool [69, 135, 136, 140]. This area is related to the DfAM field
for fighting off the COVID-19 and future pandemics. and is developing as research is done [135]. Therefore, AM
will be able to accelerate the production of tooling devices
7.2 Metal and ceramic additive manufacturing for optimized mass production. As an example made reality
during the pandemic, to achieve mass production, Catalysis
As reported, metal and ceramic AM did not show significant Additive Tooling company took 2 weeks to design and pro-
engagement during the COVID-19 pandemic. Even though duce a 3D printed metallic injection mold for manufacturing
headbands for face shields [141].
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32 Progress in Additive Manufacturing (2021) 6:19–37
A technology with great potential to help fight pandemic Additive manufacturing has emerged as an essential tech-
diseases is bioprinting. This is a technology, emerged from nology during COVID-19 pandemic. Because of the sup-
3D printing in 2003 [142], that uses bioink as deposition ply chain disruption, various devices, such as face shields,
material [143]. Groll et al. [144] define bioink as “a formu- face masks, valves, nasopharyngeal swabs, and other
lation of cells suitable for processing by an automated bio- devices were in shortage. Quick and innovative design
fabrication technology that may also contain biologically associated with AM were successfully used for production
active components and biomaterials”. Still in its infancy, of these items, saving lives from health workers, patients,
the technology can be used in regenerative medicine to and general population. These devices could be almost
support the manufacture of tissues and organs for trans- instantaneously produced in diverse parts of the world, as
plantation [145, 146]. It could also be used for producing soon a project file was projected or shared through global
lung models—or any other organ model -, which could be network, pointing out for a future reduction in logistics
used to study a disease dynamic and analyze an infected with local production. Other major features that lever-
organ response to drug targets, detecting the disease pro- aged AM role during pandemic were the great number of
gression in vitro [147, 148]. In this regard, Berg et al. 3D printers spread around the world, even in developing
[148] have shown the model ability to mimic the distribu- countries, the ease of sharing and downloading printable
tion of an influenza A virus strain in a real lung, something parts, and its ability for rapid prototyping first designs and
impossible for traditional cell culture. equipment parts. Accompanied from diverse initiatives of
companies, groups, and individuals in helping people in
need, a mass production of devices was reached.
7.6 3D printed medicines As this massive production gained the notoriety of
people and media, it also brought up some issues to be
As the pandemic diseases can easily overpass frontiers, overcome before the next emergency. The lack of central-
it is important to develop strategies for producing and ized standards and guidelines from regulatory agencies
distributing drugs to all parts of the world during supply caused different people, groups, and companies to take
chain disruptions. Regarding this, there is the possibility the initiative for producing non-validated parts from their
to 3D print oral solid dosage forms (OSDF) with differ- own experience. This issue called the need for producing
ent drugs in a customized way [140, 149]. These medi- pre-approved guidelines for these situations that will allow
cines can be produced with controlled dosages, according people to help in a short period of time, without being
to patients’ characteristics, with controlled release and, threatened by legal issues and harming final users. Fur-
most importantly in a pandemic scenario, in a decentral- thermore, intellectual property emergency laws must be
ized way [140]. Therefore, AM can be used for producing developed to ensure people lives, as during the pandemic
drugs at hot spots where conventional drugs cannot reach the supply chain disruption created a shortage of diverse
[140]. However, quality control, costs lowering, and the essential devices from medical suppliers. In this line,
selection of the AM technology according to the formula- public domain open-source equipment and devices can be
tion requirements are some key challenges that must be developed and act as an emergency option during these
addressed for this application to be viable possible future situations. Within that, scientists must work in testing and
pandemic scenarios [140]. publishing results. These works will remain in literature
as a reliable peer-reviewed data, beyond media and social
media volatile information, and will help the development
7.7 Industry 4.0 of guidelines and projects that may be centralized and stay
as resource during future pandemics.
The AM technology is described as part of Industry 4.0 [28, Finally, AM is still a relatively recent technology. Mate-
113]. Regarding this, Choong et al. [34] highlights that AM rials, techniques, software, and applications are being
machines will continue to be key parts in the cyber-physical developed daily. This will ensure that additive manufac-
post-pandemic scenario. In a review by Khan and Javaid turing will continue to be fundamental to help humanity
[150], the authors point AM machines as part of an auto- fight the next coming pandemics.
mated emergency system composed by innovative technolo-
gies, such as drones, machine learning, and artificial intel-
ligence, to quickly deliver PPE at required places without Author contributions GAL: main idea; literature search; data analysis;
draft; critical review. GBN: literature search; draft; critical review. GC:
human contact. Therefore, AM will benefit from Industry
critical review. JVLS: literature search; draft; critical review.
4.0 development.
13
Progress in Additive Manufacturing (2021) 6:19–37 33
Funding This study was funded by the National Council for Scientific 15. Tino R, Moore R, Antoline S et al (2020) COVID-19 and the role
and Technological Development (CNPq), Grants nos. 139963/2019-7, of 3D printing in medicine. 3D Print Med 6:1–8
301626/2020-0, and 301624/2020-8 and the Scientific Research Foun- 16. Tsikala Vafea M, Atalla E, Georgakas J et al (2020) Emerg-
dation for the State of São Paulo (FAPESP), Grant no. 2020/05612-8. ing technologies for use in the study, diagnosis, and treatment
of patients with COVID-19. Cell Mol Bioeng. https: //doi.
Availability of data and materials Not applicable. org/10.1007/s12195-020-00629-w
17. Das H, Patowary A (2020) Uses of 3D Printing for Production
of Ppe for Covid 19 like situations: scope and future. Am J Prev
Compliance with ethical standards Med Public Heal 6:76. https://doi.org/10.5455/ajpmph.20200
413022349
Conflicts of interest The authors declare that they have no conflict of 18. Pecchia L, Piaggio D, Maccaro A et al (2020) The inadequacy
interest. of regulatory frameworks in time of crisis and in low-resource
settings: personal protective equipment and COVID-19. Health
Technol (Berl). https://doi.org/10.1007/s12553-020-00429-2
19. Vordos N, Gkika DA, Maliaris G et al (2020) How 3D print-
ing and social media tackles the PPE shortage during COVID-
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